Structural Shape Optimization Based On The Use Of Cartesian Grids

Abstract

As ever more challenging designs are required in present-day industries, the traditional trial-and-error procedure frequently used for designing mechanical parts slows down the design process and yields suboptimal designs, so that new approaches are needed to obtain a competitive advantage. With the ascent of the Finite Element Method (FEM) in the engineering community in the 1970s, structural shape optimization arose as a promising area of application. However, due to the iterative nature of shape optimization processes, the handling of large quantities of numerical models along with the approximated character of numerical methods may even dissuade the use of these techniques (or fail to exploit their full potential) because the development time of new products is becoming ever shorter. This Thesis is concerned with the formulation of a 3D methodology based on the Cartesian-grid Finite Element Method (cgFEM) as a tool for efficient and robust numerical analysis. This methodology belongs to the category of embedded (or fictitious) domain discretization techniques in which the key concept is to extend the structural analysis problem to an easy-to-mesh approximation domain that encloses the physical domain boundary. The use of Cartesian grids provides a natural platform for structural shape optimization because the numerical domain is separated from a physical model, which can easily be changed during the optimization procedure without altering the background discretization. Another advantage is the fact that mesh generation becomes a trivial task since the discretization of the numerical domain and its manipulation, in combination with an efficient hierarchical data structure, can be exploited to save computational effort. However, these advantages are challenged by several numerical issues. Basically, the computational effort has moved from the use of expensive meshing algorithms towards the use of, for example, elaborate numerical integration schemes designed to capture the mismatch between the geometrical domain boundary and the embedding finite element mesh. To do this we used a stabilized formulation to impose boundary conditions and developed novel techniques to be able to capture the exact boundary representation of the models. To complete the implementation of a structural shape optimization method an adjunct formulation is used for the differentiation of the design sensitivities required for gradient-based algorithms. The derivatives are not only the variables required for the process, but also compose a powerful tool for projecting information between different designs, or even projecting the information to create h-adapted meshes without going through a full h-adaptive refinement process. The proposed improvements are reflected in the numerical examples included in this Thesis. These analyses clearly show the improved behavior of the cgFEM technology as regards numerical accuracy and computational efficiency, and consequently the suitability of the cgFEM approach for shape optimization or contact problems.